Automatic Cable Tester

PROJECTED CMMC LEVEL REQUIREMENT
Level 2 (Self)
TECHNOLOGY AREAS
None
MODERNIZATION PRIORITIES
Integrated Sensing and Cyber
KEYWORDS
Radio Frequency; Automatic Cable Testing; Fiber Optic Cable; Continuity Testing; Test Connectors; Resistance Testing
OBJECTIVE
Develop a low-cost and user-friendly automatic cable tester capable of universally testing continuity, resistance, and isolation of both Copper, Radio Frequency (RF) cables, and the impedance of Fiber Optic cables via Optical Time Domain Reflectometry (OTDR), while rapidly generating easily read quality assurance reports.
DESCRIPTION
While a DDG 51 Class Ship is undergoing modernization, significant time is spent testing continuity, resistance, and isolation on large numbers of Copper, RF cables, and impedance of Fiber Optic cables. For example, within the combat systems alone, there are over 2,900 interfaces that require such testing. With the numerous amounts of cables needed to be tested on board a ship, manual testing of each cable can take several hours compared to several minutes or less with utilization of an automatic tester.
While approximately 175 adapters and kits are available for automatic cable testing, there are no universal devices capable of testing Copper, RF, or Fiber cables. The automatic tester must be equipped with low-cost software and adapter kits for both the local and the remote sides of the varieties of copper cables and connectors under test. The Navy needs a cable analyzer that can perform a variety of multi-pin connections along with a Fiber Optical Loss Test Set (OLTS)/ OTDR tester capable of utilizing the existing and approved testing standards or featuring an innovative unconventional low-cost means of examining each cable and loopback.
The Navy seeks an automatic cable tester capable of testing the connectivity, continuity, and isolation of both Copper, RF and Fiber Optic cables. The development of an inexpensive, portable, universal cable tester system, able to portray data in real time is desired. The tester must be able to easily connect to the variety of connectors on the cables previously mentioned and reduce both the number of test-connectors necessary to operate as well as the overall cost of the prototype/production system. The software used by the tester should be able to be either Microsoft-based software or one easily convertible into an Excel format for recording test data. The solution should be easily transported by one sailor to allow for convenient movement through tight hatchways and spaces found within a DDG 51 Class Ship. The prototype developer should also document specifics of a life cycle management program both for the tester and all components. The developed solution should shorten the length of time required to test all connections on a ship undergoing modernization.
PHASE I
Develop a concept for an automatic cable tester and demonstrate that the concept meets all parameters in the Description. Demonstrate the feasibility of the concept in meeting Navy needs by component evaluation and analytical modeling. The Phase I Option, if exercised, should include the initial layout and capabilities to build the prototype in Phase II. Prepare a Phase II plan.
PHASE II
Develop and deliver for evaluation and testing a prototype accompanied by a complete connector kit for Navy testing. Design all system components to meet all standard Navy environmental testing. The prototype will be evaluated and tested to determine capability in meeting the performance goals defined in the Description. Develop device designs that can be efficiently fabricated/assembled and detailed plans for fabrication intended to reduce the number and/or cost of test-connectors/ devices across the spectrum of cables mentioned in the Description. Identify software concepts that can be used for testing at minimum continuity and insulation resistance testing of copper and fiber optic verification testing for performance, insertion and return loss for both single and multi-mode fiber cabling. Product performance will be demonstrated through prototype evaluation, modeling, and demonstration over the required range of parameters. An extended laboratory test will be used to refine the prototypes into a design that will meet Navy requirements. Prepare a Phase III manufacturing and development plan to transition the system to Navy use.
PHASE III DUAL USE APPLICATIONS
Support the Navy in transitioning the Automatic Cable Tester to Navy use. Develop installation, maintenance, and operations manuals for the Automatic Cable Tester to support transition to the fleet.
The finished product has potential commercial applications for commercial communication maintenance personnel.
REFERENCES
Webb, Herbert Laws. "A Practical Guide to the Testing of Insulated Wires and Cables (Classic Reprint)." Forgotten Books, 18 June 2017. https://www.abebooks.com/Practical-Guide-Testing-Insulated-Wires-Cables/30839720599/bd
Loveday, George. "Electronic Testing and Fault Diagnosis." Prentice Hall, 1995. https://archive.org/details/electronictestin0000love
Williams, Paul A. "NIST Artifact Standards for Fiber Optic Metrology." NIST, no. 1, 2000, pp. 1-5, www.nist.gov/publications/nist-artifact-standards-fiber-optic-metrology